CN108367502B - 用于连接纤维增强薄片的方法和设备 - Google Patents

用于连接纤维增强薄片的方法和设备 Download PDF

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CN108367502B
CN108367502B CN201680071682.2A CN201680071682A CN108367502B CN 108367502 B CN108367502 B CN 108367502B CN 201680071682 A CN201680071682 A CN 201680071682A CN 108367502 B CN108367502 B CN 108367502B
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sheet
sheet product
fibers
welded
welding
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CN108367502A (zh
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M·克瑙普
T·格里姆
H·伯格尔
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Covestro Deutschland AG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/087—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using both a rotary sonotrode and a rotary anvil
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8253—Testing the joint by the use of waves or particle radiation, e.g. visual examination, scanning electron microscopy, or X-rays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/435—Making large sheets by joining smaller ones or strips together
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72141—Fibres of continuous length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81463—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
    • B29C66/81469—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint one placed next to the other in a single line transverse to the feed direction, e.g. shoulder to shoulder sonotrodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • B29C66/8362—Rollers, cylinders or drums moving relative to and tangentially to the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/085—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary sonotrode
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/086—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary anvil
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8122—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81463—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81463—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
    • B29C66/81465—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint one placed behind the other in a single row in the feed direction

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

通过超声波焊接接合两个用单向排列的连续纤维增强的薄片(1)的方法和设备，其中所述纤维嵌入聚碳酸酯基体中，并且所述薄片具有基本上为正方形且基本上平整的对接端，其特征在于以下步骤：‑在焊接设备上在焊头(2)与底砧(3)之间，使薄片以对接端区域彼此相邻地排列，‑利用超声波焊接薄片，其中焊头和底砧在所述薄片之间的熔化区中垂直于薄片的对接端在待焊接的薄片上施加压力，‑从焊接设备中移出焊接在了一起的薄片(4)。

Description

用于连接纤维增强薄片的方法和设备
本发明涉及通过超声波焊接接合纤维增强片材制品的方法和设备。本发明还涉及适用于通过超声波焊接与其他同类片材制品接合的纤维增强片材制品。
纤维增强材料因其突出的特定性质，其应用在最近几十年不断增加。纤维增强材料用于特别是进行加速的结构中，以便能够减轻重量，从而使能量消耗最小化，而不发生材料的强度或刚性的损失。
纤维增强材料，也称为纤维复合物或简称为复合物，是包含基体材料的至少双相材料，在所述基体材料中基本上完全嵌入和包封了纤维。所述基体具有赋予形状的功能，旨在保护所述纤维免受外部影响，并且是在纤维之间传递力并引入外部负荷所必须的。所述纤维对于材料的机械性质具有决定性贡献，其中在工业上通常使用玻璃纤维、碳纤维、聚合物纤维、玄武岩纤维或天然纤维。根据预期的用途，所用的基体通常是热固性或热塑性聚合物，偶尔甚至为弹性体。
热固性聚合物早已在许多行业中确立。然而，决定性缺点为固化时间过长，这导致在加工以得到组件期间循环时间相应过长。这使得热固性类的复合物尤其对于大体积工业应用而言是没有吸引力的。
相比之下，热塑性类复合物只要是完全固结的半成品产品的形式，例如作为连续纤维增强片材或型材形式，那么在进行进一步处理时通常仅仅加热、形成和冷却，这目前在不到1分钟的循环时间内就可以实现。处理还可以与其他方法步骤结合，例如热塑性塑料的嵌入成型，这使得可能实现非常高度的自动化和功能集成。
纤维通常涂有所谓的胶料(size)。如果使用热塑性塑料作为基体，则对于胶料适合的胶料体系包括热塑性塑料、硅烷、环氧树脂或聚氨酯。然而，纤维或纤维的一部分也可以不包括胶料。
经常使用的增强材料为半成品纺织物，例如梭织物、针织物、多层无纬物(multi-ply laid)或无纺布(例如毛毡、无定向纤维垫(random-laid fibre mat)等)。这些形式的纤维增强材料的特征在于，在半成品纺织物中纤维的取向已经确定，由此在之后部件中力的作用轨迹已经确定。这使得可直接制备多方向增强复合物。
除了这些已经确定的基于半成品纺织物的体系之外，片状形式的基于热塑性塑料的纤维增强半成品产品正在变得越来越重要。它们由于可避开半成品纺织物制备的方法步骤而提供了经济优势。这些基于热塑性塑料的纤维增强半成品片材适用于制备多层结构，还特别适用于制备多方向结构。
在WO 2012 123 302 A1中记载了用于制备用单向排列的连续纤维增强的基于热塑性塑料的半成品片材的方法和设备，在此其公开内容以引用的方式全部纳入本发明的说明书中。所公开的方法/所公开的设备提供纤维增强半成品片材，在所述纤维增强半成品片材中连续纤维以与供应片材的延展方向成0°的方向排列。
在EP 2 631 049 A1中也记载了用于制备用单向排列的连续纤维增强的基于热塑性塑料的半成品片材的方法和设备，在此其公开内容同样以引用的方式全部纳入本发明的说明书中。
EP 2 631 049 A1的主题的特征在于，将连续纤维与供应片材的延展方向成0°方向排列的供应片材用于制备半成品片材，在所述半成品片材中所述纤维与半成品片材的延展方向成非0°方向单向排列。
在EP 2 631 049 A1中公开的方法中，为制备最终的半成品片材，即其中纤维沿着与半成品片材的延展方向成非0°方向单向排列的片材，从具有主方向、塑料基体和以单向取向的方式与延展方向成0°角度固定的许多纤维的供应片材中分离出节段，将这些节段彼此相邻排列，使得它们平行于延展方向延伸的纵向边缘彼此平行并相邻且与纵向方向成预定角度，并使相邻节段在其纵向边缘的区域彼此接合。
在EP 2 631 049 A1中公开的设备包括：分配装置，用于分配具有主方向、塑料基体和以单向取向方式与主方向成0°角度固定的许多纤维的供应片材的节段；排列装置，用于将所述节段彼此相邻排列，使得它们沿主方向平行延伸的纵向边缘彼此平行并相邻且与纵向方向成预定角度；以及接合装置，用于使相邻节段以其纵向边缘区域接合。
半成品片材制备中的决速步是，接合从供应片材切割出的片材片(在EP 2 631049 A1中称为节段)以获得最终的半成品片材。
在下文中，供应片材、片材片和最终的半成品片材也统称为片材制品。
EP 2 631 049 A1尤其建议通过粘合粘接或焊接进行该接合。EP 2 631 049 A1尤其建议超声波焊接作为焊接法。
超声波焊接本身是已知的。其为一种摩擦焊接方法，其中焊接通过通常在20至35kHz范围内的高频机械振动来实现，所述高频机械振动导致部件之间经由分子和界面摩擦而加热。
发生器用于产生高频交流电，所述交流电通过同轴电缆传输至超声换能器(所谓的转换器)，所述超声换能器利用压电效应或磁致伸缩效应由此产生机械超声振动。这些振动经由变幅杆(amplitude transformer)传输至焊头(sonotrode)。不同的应用需要不同的焊头设计，所述焊头通常由钢、铝或钛制成，并且其几何形状取决于所用发生器提供的频率以及加工任务。
焊头是通过引入高频机械振动即超声波而开始共振振动的工具。它们提供从超声发生器到工件的连接，并使超声振动适应于加工任务。焊头使用于超声波焊接中，以通过不同方法使部件在接合或接触区域产生永久接合。底砧用作焊头的基台(abutment)。
焊头和底砧是超声波焊接机中仅有的与待焊接部位直接接触的部件。因此，它们的工作面必须以这样的方式成型：超声振动被最佳地引入接合区域，并且避免在待焊接部位上有压痕。机械振动垂直地引入待焊接部位的接合区域。
当焊接塑料时，振动通常垂直地引入接合部位。塑料进行加热并开始软化，这导致阻尼系数增大。阻尼系数的增大导致更高的内摩擦，从而进一步加速温度的升高。熔化的材料接合，并在冷却和固化之后彼此焊接在一起。
除了点焊之外，辊缝焊头使得可以进行缝焊，特别以连续的方式进行。
超声波焊接的特征在于非常短的焊接时间和高的经济性。相同和不同的材料可以彼此接合，工件仅在焊接区域小程度地被加热，因此周围材料不会被损坏。
用于超声波焊接的机器是例如Nucleus GmbH,Düsseldorf所研发并销售的。这类机器的实例为ROTOSONIC V4E。
然而，基于热塑性塑料的纤维增强片材制品，如EP 2 631 049 A1中所称的节段的超声波焊接在实践中非常困难。这在文章"Advances in fusion bonding techniques forjoining thermoplastic matrix composites:a review"(C.Ageorges,L.Ye,M.Hou,Composites:Part A 32(2001)839-857)中尤其明显。该文件强调这一问题：由于纤维包含物，导致具有更少的可熔性材料，这使得更难以产生粘性接合。同一篇文章提出了叠加待接合的片材制品，然后使其在压力下进行超声波焊接的解决方案。
DE 10 2008 059 142 A1也公开了基于热塑性塑料的纤维增强片材制品的超声波焊接。同样在该文中，片材制品被叠加并施加压力，以便能够进行焊接。
然而，该过程的缺点是，在焊接之后，即在片材制品重叠的点处，片材制品显得不平整和/或增厚。这样的片材制品不再适用于要求平整表面的应用。
另一个缺点为重叠需要使用附加材料。产生重叠还需要额外的设备复杂性，这也是一个另外的缺点。
上文所列文献均没有公开使用热塑性聚碳酸酯作为基体材料来制备片材制品。
与通常使用的热塑性塑料相比，聚碳酸酯具有这样的缺点：它们几乎没有蠕变倾向，因此当在持续应力下时有开裂的倾向。这特别是对于用于含有连续纤维的复合物中而言是非常成问题的，因为在塑料基体中含连续纤维的复合物由于所述连续纤维而处于持续应力下。因此，直到现在，聚碳酸酯作为用于这类包含连续纤维的复合物的塑料基体在实践中仅起到辅助的作用。然而，原则上期望将聚碳酸酯的应用领域拓宽至也包括单向纤维增强片材制品，因为与其他常规的热塑性塑料如聚酰胺或聚丙烯相比，聚碳酸酯在固化过程中展现出减少的体积收缩。与其他热塑性塑料相比，聚碳酸酯还展现出更高的玻璃化转变温度Tg以及更高的耐热性。
此外，由含有聚碳酸酯作为基体材料的单向纤维增强片材制品制备的片材可提供具有美学上令人满意的低起伏表面以及良好的机械性能的多层复合物。由含有聚碳酸酯作为基体材料的片材构成的这类多层复合物展现出类金属的触感、光学和声学效果。
这些性质还使得这类多层复合物适合作为外壳的外壳材料(housing material)用于电子器件，特别是便携式电子设备如便携式电脑或智能手机的外壳，以及用于汽车的外部和内部装饰，因为这类多层复合物可以承受机械负荷以及提供特殊的外观。
US2014286697A1公开了一种焊接基于热塑性塑料的纤维增强片材制品的方法，其中所述片材制品不重叠。在该文中，热塑性塑料可以是聚碳酸酯，但是纤维为短纤维并以无定向的方式分布。然而，从US2014286697A1的图3显见，在焊接的区域中存在不平整和/或增厚。
本发明的一个目的为克服现有技术的缺点。本发明的一个特别的目的为提供方法和设备，使用所述方法和设备可使纤维嵌入聚碳酸酯基体中的用单向排列的连续纤维增强的片材制品通过超声波焊接而彼此粘性接合，无需片材制品彼此重叠。本发明的另一个目的为提供纤维嵌入聚碳酸酯基体中的用单向排列的连续纤维增强的片材制品，其利用超声波焊接可以粘性接合至另一个同种的纤维嵌入聚碳酸酯基体中的用单向排列的连续纤维增强的片材制品。
在本上下文中，同种应当理解为意指待接合的片材制品在物质和结构两方面上均是同种的。
片材制品应当在焊接之后不显得不平整和增厚。
该目的通过独立权利要求的主题实现。优选的实施方案见于从属权利要求中。
在本发明的上下文中，“粘性接合”应当理解为意指通过超声波焊接产生的接合，在该接合的任何点处，显示出在拉伸强度和断裂伸长率方面的值(例如均通过拉伸试验确定)为片材制品在任何所需的其他点处的拉伸强度和断裂伸长率的至少50％、优选70％、特别优选90％，片材制品上通过超声波焊接产生的接合处和任何所需的其他点处的拉伸强度和断裂伸长率的值以相同的方式确定。从通过超声波焊接产生的接合中和片材制品上的其他点中的任何所需的点中除去的是相对于片材制品的大面积(即片材制品的顶部和底部)位于10mm的边缘区域内的区域。
特别地，所述目的通过一种方法实现，所述方法通过超声波焊接接合两个用单向排列的连续纤维增强的片材制品，其中所述纤维是嵌入聚碳酸酯基体中的，其特征在于以下步骤：
(1)在焊接设备上将片材制品彼此相邻地端对端排列，
(2)利用超声波焊接片材制品，
(3)从焊接设备中移出彼此焊接的片材制品。
在本发明的上下文中，术语“端对端”应当理解为意指片材制品分别以其一个窄侧面彼此相邻排列，使得这些侧面彼此平行放置并且接触。优选片材制品的侧面基本上经过它们的整个表面接触。在本上下文中，术语“基本上经过它们的整个表面”应理解为意指基于两个侧面中的至少一个计，所述面被另一个侧面覆盖达到至少90％、优选至少95％、特别优选至少98％、非常特别优选至少99％的程度。在一般情况下涉及同种片材制品的情况下，这对两个侧面均同样适用。在本发明的上下文中，术语“端对端”不包括片材制品相互重叠的情况。
在下文中，这些侧面还被称为对接端(abutting end)。
为了获得粘性接合而不重叠的片材制品，有利的是片材制品具有基本上为矩形且基本上平整的对接端。这确保片材制品在焊接之后不显得不平整或增厚。
在本发明的上下文中，“基本上为矩形”应理解为意指至少90％、优选至少95％、特别优选至少98％的对接端面积位于矩形内，以及至少90％、优选至少95％、特别优选至少98％的该矩形区被对接端面积占据。对接端面积的突出于矩形之外的部分即凸起的最大线性尺寸分别为不多于矩形高度的10％，优选不多于5％，特别优选不多于2％，其中该尺寸分别垂直于凸起以最大程度突出的矩形的边来测定。对接端面积中突出到矩形中的凹陷的最大线性尺寸分别为矩形高度的不多于10％，优选不多于5％，特别优选不多于2％，其中该凹陷分别垂直于各个凹陷最大程度突出到其中的矩形的边来测定。所述矩形以与片材部分/片材的最大面积成85°至95°、优选88°至92°、特别优选89°至91°的角度，非常特别优选垂直地排列。矩形的宽高比为优选50:1或更大，特别优选100:1至100 000:1，特别是150:1至30000:1。
在上述变量的限定内矩形的宽度等于该点处片材制品的边长，并且在上述变量的限定内矩形的高度等于该点处片材制品的厚度。
所述宽度优选为60至2100mm，优选500至1000mm，特别优选600至800mm，以及所述厚度优选为100至350μm，优选120至200μm。然而，本发明的方法也可用于处理具有其他宽度和厚度的片材制品，特别是可处理厚度最高达1000μm以上，例如最高达1200μm或甚至最高达1500μm或甚至最高达2000μm的片材制品；即即使是具有这些厚度的片材制品，根据本发明的方法也可以产生粘性接合。
因此，对接端是一个空间尺寸为厚度的片材制品的侧面之一，决不会是面积通过片材制品的长度和宽度确定的片材制品的侧面之一。
在本发明的上下文中，“基本上平整”应理解为意指垂直于/离开平面的矩形平面外的凹陷或凸起的最大线性尺寸不超过矩形高度的最多20μm，优选最多15μm，特别优选最多10μm％，非常特别优选最多5μm。
在本发明的上下文中，“片材制品在焊接之后不显得不平整或增厚”应当理解为意指焊接接合处片材制品的厚度与焊接接合处之外片材制品的厚度相比偏差不多于20％，优选不多于15％，特别优选不多于10％，非常特别优选不多于5％。
例如在EP 2 631 049 A1中公开的，切割出片材片的供应片材的长度为100至3000m，并且这同样适用于最终的半成品片材。片材片的长度为60至2100mm，优选500至1000mm。这同样适用于宽度和长度，并且片材制品的宽度可相同或不同。
优选片材制品的大的面积为平行四边形形状，特别是矩形，非常尤其地为正方形形状。
供应片材以及由此片材片和最终的半成品片材具有基体，所述基体包含至少50重量％、优选至少70重量％、特别优选至少90重量％、非常特别优选至少95重量％、特别至少97重量％程度的基于聚碳酸酯的热塑性塑料。
当在本文中涉及聚碳酸酯时，这也包括不同聚碳酸酯的混合物。在本文中，聚碳酸酯还用作涵盖性术语，因此包括均聚碳酸酯和共聚碳酸酯。聚碳酸酯还可为已知形式的线性或支化的。
优选所述聚氨酯包含70重量％、优选80重量％、特别优选90重量％程度，或基本上，特别是100重量％程度的线性聚碳酸酯。
聚碳酸酯可以已知方式由二酚、碳酸衍生物和任选的链终止剂和支化剂制备。与聚碳酸酯的制备有关的细节至少约40年来都是本领域技术人员熟知的。在本文中，可参考例如Schnell,Chemistry and Physics of Polycarbonates,Polymer Reviews,第9卷,Interscience Publishers,New York,London,Sydney 1964；D.Freitag,U.Grigo,P.R.Müller,H.Nouvertné,BAYER AG,Polycarbonates in Encyclopedia of Polymer Scienceand Engineering,第11卷,第二版,1988,第648-718页；以及最后U.Grigo,K.Kirchner和P.R.Müller Polycarbonate in BeckerBraun,Kunststoff-Handbuch,第31卷,Polycarbonate,Polyacetale,Polyester,Celluloseester,Carl Hanser Verlag Munich,Vienna 1992,第117-299页。
芳族聚碳酸酯例如通过界面法，使双酚与羰基卤化物优选光气，和/或与芳族二羰基二卤化物优选苯二羰基二卤化物反应来制备，任选伴随使用链终止剂以及任选伴随使用三官能或大于三官能的支化剂。也可以经由熔融聚合方法通过二酚与例如碳酸二苯酯的反应制备。适于制备聚碳酸酯的二酚为例如氢醌、间苯二酚、二羟基联苯、双(羟基苯基)烷烃、双(羟基苯基)环烷烃、双(羟基苯基)硫化物、双(羟基苯基)醚、双(羟基苯基)酮、双(羟基苯基)砜、双(羟基苯基)亚砜、α,α'-双(羟基苯基)二异丙基苯、衍生自靛红衍生物或酚酞衍生物的苯并吡咯酮(phthalimidine)，以及相关的环烷基化、环芳基化和环卤代的化合物。
优选使用的二酚为基于邻苯二甲酰亚胺的那些二酚，例如2-芳烷基-3,3'-双(4-羟基苯基)邻苯二甲酰亚胺或2-芳基-3,3'-双(4-羟基苯基)邻苯二甲酰亚胺如2-苯基-3,3'-双(4-羟基苯基)邻苯二甲酰亚胺,2-烷基-3,3'-双(4-羟基苯基)邻苯二甲酰亚胺如2-丁基-3,3'-双(4-羟基苯基)邻苯二甲酰亚胺、2-丙基-3,3'-双(4-羟基苯基)邻苯二甲酰亚胺、2-乙基-3,3'-双(4-羟基苯基)邻苯二甲酰亚胺或2-甲基-3,3'-双(4-羟基苯基)邻苯二甲酰亚胺；以及基于在氮上被取代的靛红的二酚如3,3-双(4-羟基苯基)-1-苯基-1H-吲哚-2-酮或2,2-双(4-羟基苯基)-1-苯基-1H-吲哚-3-酮。
优选的二酚为4,4'-二羟基联苯、2,2-双(4-羟基苯基)丙烷(双酚A)、2,4-双(4-羟基苯基)-2-甲基丁烷、1,1-双(4-羟基苯基)-对-二异丙基苯、2,2-双(3-甲基-4-羟基苯基)丙烷、二甲基双酚A、双(3,5-二甲基-4-羟基苯基)甲烷、2,2-双(3,5-二甲基-4-羟基苯基)丙烷、双(3,5-二甲基-4-羟基苯基)砜、2,4-双(3,5-二甲基-4-羟基苯基)-2-甲基丁烷、1,1-双(3,5-二甲基-4-羟基苯基)-对二异丙基苯和1,1-双(4-羟基苯基)-3,3,5-三甲基环己烷。
特别优选的二酚为2,2-双(4-羟基苯基)丙烷(双酚A)、2,2-双(3,5-二甲基-4-羟基苯基)丙烷、1,1-双(4-羟基苯基)环己烷、1,1-双(4-羟基苯基)-3,3,5-三甲基环己烷和二甲基双酚A。
这些和其他合适的二酚记载于例如US-A 3 028 635、US-A 2 999 825、US-A 3148 172、US-A 2 991 273、US-A 3 271 367、US-A 4 982 014和US-A 2 999 846，记载于DE-A 1 570 703、DE-A 2063 050、DE-A 2 036 052、DE-A 2 211 956和DE-A 3 832 396，记载于FR-A 1 561 518中，记载于专著H.Schnell,Chemistry and Physics ofPolycarbonates,Interscience Publishers,New York 1964以及JP-A 620391986、JP-A620401986和JP-A 1055501986中。
在均聚碳酸酯的情况下，仅使用一种二酚，并且在共聚碳酸酯的情况下，使用两种或更多种二酚。
合适的碳酸衍生物的实例包括光气或碳酸二苯酯。可用于制备聚碳酸酯的合适的链终止剂为一元酚。合适的一元酚为例如苯酚自身、烷基酚如甲酚、对叔丁基酚、枯基酚以及其混合物。
优选的链终止剂为被线状或支化的、优选未取代的C1至C30烷基或被叔丁基单取代或多取代的酚。特别优选的链终止剂为苯酚、枯基酚和/或对叔丁基酚。待使用的链终止剂的量为优选0.1至5摩尔％，基于分别使用的二酚的摩尔数计。可在与碳酸衍生物反应之前、过程中或之后添加链终止剂。
合适的支化剂是聚碳酸酯化学中所熟悉的三官能或大于三官能的化合物，特别是具有三个或大于三个酚OH基团的那些化合物。
合适的支化剂为例如1,3,5-三(4-羟基苯基)苯、1,1,1-三(4-羟基苯基)乙烷、三(4-羟基苯基)苯基甲烷、2,4-双(4-羟基苯基异丙基)酚、2,6-双(2-羟基-5'-甲基苄基)-4-甲基酚、2-(4-羟基苯基)-2-(2,4-二羟基苯基)丙烷、四(4-羟基苯基)甲烷、四(4-(4-羟基苯基异丙基)苯氧基)甲烷以及1,4-双((4',4-二羟基三苯基)甲基)苯以及3,3-双(3-甲基-4-羟基苯基)-2-氧代-2,3-二氢吲哚。
任选使用的支化剂的量优选为0.05摩尔％至3.00摩尔％，每种情况下基于所用的二酚的摩尔数计。支化剂可以最初就与二酚和链终止剂一起加入碱水相中或以溶于有机溶剂中的形式加入，然后光气化。在酯交换方法的情况下，支化剂与二酚一起使用。
特别优选的聚碳酸酯为基于双酚A的均聚碳酸酯、基于1,3-双(4-羟基苯基)-3,3,5-三甲基环己烷的均聚碳酸酯以及基于两种单体双酚A和1,1-双(4-羟基苯基)-3,3,5-三甲基环己烷的共聚碳酸酯。
另外，还可使用共聚碳酸酯。为了制备这些共聚碳酸酯，可使用基于所使用的二酚的总量计1至25重量％，优选2.5重量％至25重量％，特别优选2.5重量％至10重量％的具有羟基芳基氧基端基的聚二有机硅氧烷。这些是已知的(US 3 419 634、US-PS 3 189 662、EP0 122 535、US 5 227 449)并可通过文献已知的方法制备。同样合适的是含聚二有机硅氧烷的共聚碳酸酯；含聚二有机硅氧烷的共聚碳酸酯的制备记载于例如DE-A 3 334 782中。
聚碳酸酯可单独存在或作为聚碳酸酯的混合物存在。也可以将聚碳酸酯或聚碳酸酯的混合物与作为共混配合物(blend partner)的一种或多种不同于聚碳酸酯的塑料一起使用。
可使用的共混配合物包括聚酰胺，聚酯特别是聚对苯二甲酸丁二醇酯和聚对苯二甲酸乙二醇酯、聚交酯、聚醚、热塑性聚氨酯、聚缩醛、含氟聚合物特别是聚偏氟乙烯，聚醚砜，聚烯烃特别是聚乙烯和聚丙烯，聚酰亚胺，聚丙烯酸酯特别是聚甲基丙烯酸甲酯、聚苯醚、聚苯硫醚、聚醚酮、聚芳基醚酮，苯乙烯聚合物特别是聚苯乙烯，苯乙烯共聚物特别是苯乙烯丙烯腈共聚物、丙烯腈丁二烯苯乙烯嵌段共聚物和聚氯乙烯。
任选地还可存在基于热塑性塑料的重量计最高达50.0重量％，优选0.1至40重量％，特别优选0.2至30.0重量％的其他常规添加剂。
该常规添加剂包括阻燃剂，防滴淌剂(anti-drip agent)，热稳定剂，脱模剂，抗氧化剂，UV吸收剂，IR吸收剂，抗静电剂，荧光增白剂，光散射剂，着色剂如颜料，包括有机颜料、炭黑和/或染料，以及无机填料，其量为常规用于聚碳酸酯的量。这些添加剂可单独添加或以混合物添加。
在聚碳酸酯的情况下，通常添加的这类添加剂记载于例如EP-A 0 839 623、WO-A96/15102、EP-A 0 500 496或"Plastics Additives Handbook",Hans Zweifel,第5版2000,Hanser Verlag,Munich中。
通常有用的是将热稳定剂和流动性改进剂添加至用于基体的聚碳酸酯中，条件是它们不会降低聚碳酸酯的分子量和/或降低维卡温度(Vicat temperature)。
根据本发明所用的纤维特别是天然纤维或人造纤维或两者的混合物。天然纤维优选为纤维状矿物或植物纤维，并且人造纤维优选为无机合成纤维或有机合成纤维。根据本发明，优选玻璃纤维、碳纤维或聚合物纤维，进一步优选玻璃纤维或碳纤维。
非常特别优选使用弹性模量(E-modulus)大于240GPa，优选大于245GPa，特别优选250GPa或更高的玻璃纤维或碳纤维。特别优选具有这些性质的碳纤维。这样的碳纤维从Mitsubishi Rayon CO.,LtD.以商品名Pyrofil市售可得。
在片材制品中的纤维的体积含量平均占各个片材制品的体积的20至80体积％，优选30至70体积％，特别优选40至60体积％，非常特别优选45至55体积％。
根据本发明有利的是，片材制品的彼此焊接的区域，即进入彼此焊接接合的区域，比片材制品的其余区域具有更低的纤维含量。优选片材制品的彼此焊接的区域具有的纤维含量为片材制品的其余区域的一半或更少，特别优选五分之一或更少，非常特别优选十分之一或更少，特别是一百分之一或更少。片材制品的彼此焊接的这些区域还称为熔融区。因此在这些区域存在足够用的可熔融材料以产生粘性接合。
该熔化区自然位于片材制品的表面。熔化区优选在对接端区域中，更优选延伸穿过整个对接端。
根据本发明优选地，熔化区深度为0.1mm至3mm，优选0.2mm至2mm，特别优选0.5mm至1mm，垂直于对接端向内测量到片材制品中。
这样在超声波焊接的情况下也可以可靠地确保粘性接合而不必重叠待焊接的片材制品。相反，避免了待焊接的片材制品的重叠。
根据本发明还优选地，在焊接过程中，片材制品相对于彼此被引导，优选以对接端压靠，使得两个相对的对接端彼此直接接触并且优选彼此施加压力。该相对于彼此的引导，优选彼此压靠可使用设备机械地实现，例如经由进料装置和/或压具；或在最简单的情况下以手动实现。
在本发明的方法的一个实施方案中，彼此相邻端对端排列的片材制品放置在焊头与底砧之间并用压具压紧。焊头和底砧在彼此平行的两个线性轴之间被引导。焊头和底砧尽可能精准地沿着彼此接触的对接端被引导，焊头的宽度至少覆盖两个片材制品的熔化区。优选焊头比两个片材制品的熔化区宽度的总和宽至少10％，优选至少50％，特别优选至少100％。
所述方法达到的前进速率为1至30m每分钟，优选5至15m每分钟。
本发明还提供实施根据本发明的方法的设备，用于通过超声波焊接接合两个纤维增强片材制品，其中所述设备包括以下组件：
(A)进料装置，
(B)焊头，
(C)底砧。
根据本发明有利地，焊头为辊缝焊头，优选平滑、无型面的焊头。当伴随使用的底砧为砧轮或砧辊时，该优点可被增强。这使得具有长对接端的平整片材制品将被以高前进速率焊接。
或者，焊头还可在曲面，即接触半成品片材的表面上展现滚花(knurling)。该滚花优选蔓延至焊头的整个曲面。该滚花优选具有0.01至5mm，特别优选0.1至2mm的深度。另外优选地，所述滚花以与半成品片材的延展方向成30至150°，优选60至120°，特别优选75至105°的角度排列。该滚花例如可为从左到右滚花的形式。
焊头和底砧以以下方式布置成对：所述对将压力施加在待焊接的片材制品上，即待焊接的片材制品之间的熔化区中，并垂直于片材制品的对接端。这确保片材制品可粘性接合，无需片材制品彼此重叠。
在根据本发明的一个实施方案中，设备在进料装置与焊头之间优选还包含两个线性轴，用于引导片材制品彼此焊接。根据本发明还优选设备在焊头前面包括压具，作为两个线性轴的替代或补充。
在高前进速率，例如所述的1至30m每分钟，优选5至15m每分钟下，有利地，根据本发明的设备包含后随压辊，因为在焊接之后熔化区在高前进速率下经常不能足够快地冷却，因此不能立即提供持久粘性接合所必须的强度。已彼此焊接的片材制品通过压辊局部地固定它们的形状，从而就给予它们足够的时间来冷却和建立所需的强度。这还确保片材制品可以粘性接合，而无需片材制品彼此重叠。
为了能够沿着相对长的对接端快速且有效地进行焊接，另外有利地为所述设备包括两个、三个、四个、五个或更多个焊头，其中所述焊头可以在其辊动方向上沿着接合区域一个接一个地排列。那么所述设备包含与焊头数量相等的数个底砧，以及优选还包含相等数量的后随压辊。或者，砧轮还可全部或部分被一个或多个砧辊替代。
当所述设备包含多于一个焊头时，所有焊头可具有平整表面或所有焊头可具有有滚花的表面，或者部分焊头具有平整表面而另一部分焊头具有有滚花的表面。
本发明还提供纤维增强的片材制品，其具有含有一种或多种热塑性塑料的基体以及具有至少一个熔化区，即比片材制品的其余区域具有更低的纤维含量的区域，优选为片材制品其余区域的纤维含量的一半或更少，特别优选五分之一或更少，非常特别优选十分之一或更少，特别是一百分之一或更少。
所述纤维可以以下形式存在于基体中：梭织物(wovens)、针织物(knits)、多层无纬物(multi-ply laids)、无纺布(例如毛毡、无定向纤维垫等)、单向或多向排列的连续纤维或随机分配的短纤维。所述纤维优选以单向排列的连续纤维的形式存在。
“连续纤维(endless fibre)”应理解为意指所述纤维的长度基本上等于待增强的片材制品在纤维方向上的尺寸。与“纤维”相关的“单向”应理解为意指片材制品中的纤维仅以一个方向排列。
片材制品可为供应片材、片材片或最终的半成品片材，其中该片材制品具有说明书上文中所列的特征。
片材制品优选包含至少两个熔化区。当片材制品具有至少两个熔化区时，它们优选地排列使得至少其中的两个彼此平行。以此方式，将片材片彼此同时或相继焊接或将片材片与最后的半成品片材的末端焊接，可以制备和加长所述半成品片材。
然而，片材制品也可包含三个、四个、五个、六个或更多个熔化区。这也取决于例如片材制品的形状。因此，平行四边形形状的片材制品优选具有两个或四个熔化区，更优选两个。六边形形式的片材制品还可具有六个熔化区；在等边六边形的情况下，它们可用于由许多个通过超声波焊接而制备提供无间隙覆盖的较大表面的片材制品。
例如对于EP 2 631 049 A1的供应片材，熔化区优选为两个平行的外侧。而片材片——在EP 2 631 049 A1中称为节段——是从该供应片材中切割出；因此这些片材片也具有两个熔化区。因为随后片材片在并非原始前进方向的方向上进一步传输而片材片本身的原始排列并不发生改变，所以片材片的熔化区现在处于这样的位置：两个片材片的熔化区或者一个片材片的熔化区与最后的半成品片材的末端平行排列并彼此齐平相对。然后最后的半成品片材的末端仅具有一个熔化区，所述熔化区与片材片的熔化区齐平相对排列。
本发明还提供本发明的片材制品以片材片的构造用于通过超声波焊接制备纤维增强的成品片材的中用途。
这类片材使得可以制备多层复合物，所述多层复合物展现美学上令人满意的低起伏表面以及良好的机械性质。这类由含有聚碳酸酯作为基体材料的片材制品构造的多层复合物展现出类金属的触感、光学和声学效果，因此还适合作为外壳材料用于电子器件、特别是便携式电子器件如便携式电脑或智能手机的外壳，以及用于汽车的外部和内部装饰，因为这类多层复合物可以承受机械负荷以及提供特殊的外观。该多层复合物可由两个、三个、四个、五个、六个或更多个片材制品制备。
本发明优选的实施方案通过以下附图来描述，而并非因此将本发明限定于这些实施方案。
图1:示出了用于实施本发明的仅用一个焊头通过超声波焊接接合两个纤维增强片材制品的方法的设备的俯视图，其中附图标记具有以下含义：
1 片材切片
2 辊缝焊头
3 压辊
4 最终的半成品片材
5 焊接接合处
6 片材制品和最终的半成品片材的前进方向
7 超声波焊接过程中辊缝焊头和压辊的操作方向
图2:示出用于实施本发明的用两个焊头通过超声波焊接接合两个纤维增强片材制品的方法的设备的平面图，其中附图标记具有以下含义：
1 片材切片
2 辊缝焊头
3 压辊
4 最终的半成品片材
5 焊接接合处
6 片材制品和最终的半成品片材的前进方向
7 超声波焊接过程中辊缝焊头和压辊的操作方向
图3:示出用于实施本发明的通过超声波焊接接合两个纤维增强片材制品的方法的设备的侧视图，其中附图标记具有以下含义：
1 片材切片
2 辊缝焊头
3 砧辊
4 最终的半成品片材
5 片材切片的熔化区
6 最终的半成品片材的熔化区
图4示出了纤维增强半成品片材在焊接接合区域中的截面的明视场反射光显微照片，其中测量的厚度为186μm。
图5示出了与图5中相同的纤维增强半成品片材在焊接接合区域之外的截面的明视场反射光显微照片，其中测量的半成品片材的厚度为204μm。

Claims (23)

1.通过超声波焊接接合两个用单向排列的连续纤维增强的片材制品的方法，其中所述纤维嵌入聚碳酸酯基体中，并且所述片材制品具有基本上为矩形且基本上平整的对接端，其中片材制品的彼此焊接的区域的纤维含量为片材制品的其余区域的纤维含量的一半或更少，所述方法的特征在于以下步骤：
(1)在焊接设备上在焊头与底砧之间，使片材制品以对接端区域端对端的方式彼此相邻地排列，
(2)利用超声波焊接片材制品，其中焊头和底砧在片材制品之间的熔化区中垂直于片材制品的对接端在待焊接的片材制品上施加压力，其中已彼此焊接的片材制品通过后随压辊而局部地固定其形状，
(3)从焊接设备中移出彼此焊接的片材制品。
2.权利要求1的方法，其特征在于，所用的纤维为天然纤维或人造纤维或两者的混合物。
3.权利要求2的方法，其特征在于，所述天然纤维为纤维状矿物或植物纤维，并且所述人造纤维为无机合成纤维或有机合成纤维。
4.权利要求3的方法，其特征在于所述人造纤维为玻璃纤维、碳纤维或聚合物纤维。
5.权利要求4的方法，其特征在于所述人造纤维为玻璃纤维或碳纤维。
6.权利要求1的方法，其特征在于，所述片材制品中纤维的体积含量分别为20至80体积％。
7.权利要求6的方法，其特征在于，所述片材制品中纤维的体积含量分别为30至70体积％。
8.权利要求7的方法，其特征在于，所述片材制品中纤维的体积含量分别为40至60体积％。
9.权利要求8的方法，其特征在于，所述片材制品中纤维的体积含量分别为45至55体积％。
10.权利要求1的方法，其特征在于片材制品的彼此焊接的区域比片材制品的其余区域具有更低的纤维含量，其中片材制品的彼此焊接的区域的纤维含量为片材制品的其余区域的纤维含量的五分之一或更少，并且片材制品的彼此焊接的区域在对接端的区域中，且深度为0.1mm至3mm，垂直于对接端向内测量到片材制品中。
11.权利要求10的方法，其特征在于片材制品的彼此焊接的区域的纤维含量为片材制品的其余区域的纤维含量的十分之一或更少。
12.权利要求11的方法，其特征在于片材制品的彼此焊接的区域的纤维含量为片材制品的其余区域的纤维含量的一百分之一或更少。
13.权利要求10的方法，其特征在于片材制品的彼此焊接的区域的深度为0.2mm至2mm，垂直于对接端向内测量到片材制品中。
14.权利要求13的方法，其特征在于片材制品的彼此焊接的区域的深度为0.5mm至1mm，垂直于对接端向内测量到片材制品中。
15.通过权利要求1至14中任一项的方法制备的片材制品，其特征在于，焊接接合处片材制品的厚度与焊接接合处之外片材制品的厚度相比偏离不多于20％。
16.权利要求15的片材制品，其特征在于，焊接接合处片材制品的厚度与焊接接合处之外片材制品的厚度相比偏离不多于15％。
17.权利要求16的片材制品，其特征在于，焊接接合处片材制品的厚度与焊接接合处之外片材制品的厚度相比偏离不多于10％。
18.权利要求17的片材制品，其特征在于，焊接接合处片材制品的厚度与焊接接合处之外片材制品的厚度相比偏离不多于5％。
19.权利要求15-18中任一项的片材制品以片材片的构造用于通过超声波焊接制备纤维增强的成品片材的用途。
20.由两个或更多个权利要求15-18中任一项的片材制品构成的多层复合物。
21.权利要求20的多层复合物作为外壳的外壳材料用于电子器件，以及用于汽车的外部和内部装饰的用途。
22.权利要求21的用途，其特征在于所述电子器件为便携式电子设备。
23.权利要求22的用途，其特征在于所述便携式电子设备为便携式电脑或智能手机。
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